transmission YAMAHA VERSITY 300 2004 Owners Manual

PRE-OPERATION CHECKS
4The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or
loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual
inspection, to check the following points before each ride.
EAU03439
Pre-operation check list
ITEM CHECKS PAGE
•Check fuel level in fuel tank.
Fuel•Refuel if necessary. 3-3 — 3-4, 3-10 — 3-11
•Check fuel line for leakage.
•Check oil level in engine.
Engine oil•If necessary, add recommended oil to specified level. 6-13 — 6-15
•Check vehicle for oil leakage.
Final transmission oil•Check vehicle for oil leakage. 6-16
•Check coolant level in reservoir.
Coolant•If necessary, add recommended coolant to specified level. 6-17
•Check cooling system for leakage.
•Check operation.
•If soft or spongy, have Yamaha dealer bleed hydraulic system.
Front brake•Check fluid level in reservoir. 3-9, 6-23 — 6-25
•If necessary, add recommended brake fluid to specified level.
•Check hydraulic system for leakage.
•Check operation.
•If soft or spongy, have Yamaha dealer bleed hydraulic system.
Rear brake•Check fluid level in reservoir. 3-9, 6-23 — 6-25
•If necessary, add recommended brake fluid to specified level.
•Check hydraulic system for leakage.
4-1

OPERATION AND IMPORTANT RIDING POINTS
5
EAU04755
Tips for reducing fuel
consumption
Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:
•Avoid high engine speeds during
acceleration.
•Avoid high engine speeds with no
load on the engine.
•Turn the engine off instead of
letting it idle for an extended
length of time (e.g., in traffic jams,
at traffic lights or at railroad
crossings).
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Engine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1,600 km. For this
reason, you should read the following
material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1,600 km. The various parts in the
engine wear and polish themselves to
the correct operating clearances.
During this period, prolonged full-
throttle operation or any condition that
might result in engine overheating must
be avoided.
EAU03845*
0 — 1,000 km
Avoid prolonged operation above 1/3
throttle.
1,000 — 1,600 km
Avoid prolonged operation above 1/2
throttle.
ECA00138
After 1,000 km of operation, be sure
to replace the engine oil and final
transmission oil.
1,600 km and beyond
The vehicle can now be operated
normally.
EC000049
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.
CAUTION:
CAUTION:
5-4

EAU00462
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit ........................................................ 6-1
Periodic maintenance and lubrication chart ............ 6-2
Removing and installing cowlings and panels ........ 6-5
Checking the spark plug ....................................... 6-11
Engine oil .............................................................. 6-13
Final transmission oil ............................................ 6-16
Coolant .................................................................. 6-17
Air filter and the V-belt case air filter elements ...... 6-18
Adjusting the carburetor ........................................ 6-20
Adjusting the throttle cable free play ..................... 6-20
Adjusting the valve clearance ............................... 6-21
Tires ...................................................................... 6-21
Cast wheels .......................................................... 6-23
Adjusting the front and rear brake lever
free play ................................................................ 6-23
Checking the front and rear brake pads ................ 6-24
Checking the brake fluid level ............................... 6-24
Changing the brake fluid ....................................... 6-25Checking and lubricating the cables ..................... 6-26
Checking and lubricating the throttle grip
and cables ............................................................. 6-26
Lubricating the front and rear brake levers ........... 6-26
Checking and lubricating the centerstand
and sidestand ........................................................ 6-27
Checking the front fork .......................................... 6-27
Checking the steering ........................................... 6-28
Checking the wheel bearings ................................ 6-29
Battery ................................................................... 6-29
Replacing the fuses .............................................. 6-30
Replacing a headlight bulb .................................... 6-32
Replacing a front turn signal light bulb .................. 6-34
Replacing tail/brake light bulb
or rear turn signal light bulb .................................. 6-34
Replacing the license plate light bulb .................... 6-35
Troubleshooting ..................................................... 6-35
Troubleshooting charts .......................................... 6-36
6

PERIODIC MAINTENANCE AND MINOR REPAIR
6
•Change. (See page 3-7 for more information about the√When the oil change indicator comes on19 Engine oil oil change indicator)( Every 3000 km)
•Check oil level and vehicule for oil leakage. Every 3,000 km√
20 * Engine oil strainer•Clean.√
21 * Cooling system•Check coolant level and vehicule for coolant leakage.√√√√ √•Change. Every 3 years
22Final transmission oil•Check vehicle for oil leakage.√√ √•Change.√√√
23 * V-belt•Replace. Every 20,000 km
24 *Front and rear brake
•Check operation.√√√√√ √
switches
25 Moving parts and cables•Lubricate.√√√√ √
Throttle grip housing•Check operation and free play.
26 *
and cable•Adjust the throttle cable free play if necessary.√√√√ √
•Lubricate the throttle grip housing and cable.
27 *Lights, signals•Check operation.
√√√√√ √
and switches•Adjust headlight beam.
ODOMETER READING (x 1,000 km)
NO. ITEMCHECK OR MAINTENANCE JOB
1
ANNUAL
CHECK
10 20 30 40
EAU03884*
NOTE :
•The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
•Hydraulic brake service
•Regularly check and, if necessary, correct the brake fluid level.
•Every two years change the brake fluid.
•Replace the brake hoses every four years and if cracked or damaged.
6-4

PERIODIC MAINTENANCE AND MINOR REPAIR
6
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Final transmission oil
The final transmission case must be
checked for oil leakage before each
ride. If any leakage is found, have a
Yamaha dealer check and repair the
scooter. In addition, the final transmis-
sion oil must be changed as follows at
the intervals specified in the periodic
maintenance and lubrication chart.
1. Start the engine, warm it up by
riding the scooter for several mi-
nutes, and then stop the engine.
2. Place the scooter on the
centerstand.
3. Place an oil pan under the final
transmission case to collect the
used oil.4. Remove the oil filler cap and drain
bolt to drain the oil from the final
transmission case.
5. Install the final transmission oil
drain bolt, and then tighten it to
the specified torque.
Tightening torque:
Final transmission oil drain bolt:
22 Nm (2.2 m
•kgf)
6. Add the specified amount of the
recommended final transmission
oil, and then install and tighten the
oil filler cap.
1. Final transmission oil filler cap1. Final transmission oil drain bolt
Recommended final transmission
oil:
See page 8-2.
Oil quantity:
0.25 L
EWA00062
•Make sure that no foreign
material enters the final trans-
mission case.
•Make sure that no oil gets on
the tire or wheel.
7. Check the final transmission case
for oil leakage. If oil is leaking,
check for the cause.
WARNING
6-16
1
ZAUM0441
11
ZAUM0442

SPECIFICATIONS
8
Transmission oil:
Type Engine oil SAE 10W30
(API SE)
Total amount 0.25L
Coolant system capacity:
(including all routes)1.6L
Air filter:Wet type element.
Fuel:
Recommended fuel REGULAR UNLEADED
GASOLINE ONLY
Fuel tank capacity 10.9L
Carburetor:
Type / quantity TK5SE x 1
Manufacturer TK
Spark plug:
Type / Manufacturer DR8EA / NGK
Spark plug gap 0.6—0.7 mm
Clutch type:Dry, centrifugal automatic
Transmission:
Primary reduction system Helical gear
Primary reduction ratio 40/15 (2.666)
Secondary reduction system Helical gear
Secondary reduction ratio 37/12 (3.083)
Transmission type V-belt automatic
Operation Centrifugal automatic typeChassis:
Frame type Steel tube underbone
Caster angle ((degree)) 26°
Trail 90 mm
Tires:
Front:
Type Tubeless
Size 120/80-14 58P
Manufacturer / Model MICHELIN / PILOT CITY TL
Rear:
Type Tubeless
Size 150/70-14 66P
Manufacturer / Model MICHELIN / PILOT CITY TL
Maximum load * 202 Kg
Air pressure (cold tire):
Up to 90 kg load*
Front 180 kpa (1.8 kgf/cm
2, 1.8 Bar)
Rear 190 kpa (1.9 kgf/cm2, 1.9 Bar)
90 kg load — 160 kg load *
Front 180 kpa (1.8 kgf/cm
2, 1.8 Bar)
Rear 200 kpa (2.0 kgf/cm2, 2.0 Bar)
160 kg load — maximum
load *
Front 190 kpa (1.9 kgf/cm
2, 1.9 Bar)
Rear 220 kpa (2.2 kgf/cm2, 2.2 Bar)
* Total weight of rider, passenger, cargo and accessories.
8-2

INDEX
A
Acceleration and deceleration ............. 5-3
Air filter and V-belt case air filter
elements, cleaning ....................... 6-18
Anti-theft alarm (optional) ................... 3-7
Auxiliary DC jack ............................... 3-18
Anti-theft device housing ................... 3-14
B
Battery .............................................. 6-29
Battery voltage / coolant
temperature gauge ......................... 3-3
Brake fuid level, checking ................. 6-24
Brake fluid, changing ........................ 6-25
Bake lever, front .................................. 3-9
Brake lever, rear .................................. 3-9
Brake levers, lubricating .................... 6-26
Brake pads, checking ........................ 6-24Braking ................................................ 5-3
C
Cables, checking and lubricating ...... 6-26
Carburator, adjusting ......................... 6-20
Care .................................................... 7-1
Catalytic converter ............................ 3-11
Centerstand and sidestand, checking
and lubricating .............................. 6-27
Conversion table ................................. 8-4
Coolant .............................................. 6-17
Cowlings and panels, removing
and installing .................................. 6-5
E
Engine break-in ................................... 5-4
Engine oil .......................................... 6-13
F
Final transmission oil ........................ 6-16
Front and rear brake lever free play,
adjusting ....................................... 6-23
Front fork, checking ........................... 6-27
Fuel ................................................... 3-10
Fuel consumption, tips for reducing .... 5-4
Fuel gauge .......................................... 3-3
Fuel tank cap .................................... 3-10Fuses, replacing ................................ 6-30
H
Handlebar switches ............................. 3-8
Dimmer switch ............................... 3-8
Engine stop switch ......................... 3-8
Horn switch .................................... 3-8
Hazard switch ................................ 3-9
Pass switch .................................... 3-8
Start switch .................................... 3-8
Turn signal switch ........................... 3-8
Headlight bulb, replacing ................... 6-32
I
Identification number ........................... 9-1
Ignition circuit cut-off system ............. 3-16
Indicator lights ..................................... 3-2
High beam indicator light ............... 3-2
Low beam indicator light ................ 3-2
Turn signal indicator lights .............. 3-2
K
Key identification number .................... 9-1
L
License plate liht bulb, replacing ....... 6-35